Guidance for Designing Guidance for Designing 1. Structural strength 10 1-1. Strength of ALPOLIC panel 10 1-2. Deforming due to shearing force 11 1-3. Strength of sub-structure 11 1-4. Strength of junction hole 11 2. Thermal expansion 12 3. Thermal insulation 12 4. Waterproofing 13 5. Panel layout and special panel details 14 6. Protection against lightning 14 Appendix 1: Structural strength of ALPOLIC /fr 15 Appendix 2: Structural calculation method of ALPOLIC /fr 23 Appendix 3: Deforming due to shearing force 31 Appendix 4: Strength of sub-structure 33 Appendix 5: Strength of junction hole 36 Appendix 6: Heat transmittance of external cladding 37 Appendix 7: General performance of sealant 42 Appendix 8: Protection against lightning 43 9
Guidance for Designing One of the most important works throughout ALPOLIC /fr work is to complete the shop drawing in conformity with the architectural drawings and the requirements peculiar to the project. In order to complete the shop drawing, we have to consult well about the panel layout, installation details and so on with the architect and the client. At the same time, we have to verify that the installation method totally conforms to the project specifications. On most ALPOLIC /fr projects, the following items will be studied as fundamentals of the design: 1. Structural strength 2. Thermal expansion 3. Thermal insulation 4. Waterproofing 5. Panel layout and special panel detail We will look over these items in this section. 1. Structural strength Whenever ALPOLIC /fr panels are used outdoors, the panels and the sub-structure must withstand outdoor wind load. When wind blows toward panels, the panels and the sub-structure will be pushed with positive pressure, and accordingly deflection will occur. If the deflection is small enough and is within the elasticity range, the panels and the sub-structure will be restored to the original position when the wind load is eliminated. ALPOLIC /fr panels on the opposite side of the building, on the contrary, will be pulled with suction (negative) pressure, and a tension will occur in junction points. In the event that the pulling load is extremely large, the junction may be torn off. Thus, we have to study overall structural strength of the installation system, based on the design wind load specified for the project. 1-1. Strength of ALPOLIC /fr panel Calculation of permanent deformation: The strength of ALPOLIC /fr panels comes from its aluminum skins. Namely, if the stress exerted in aluminum skins is smaller than the permissible range, permanent deformation will not occur. In this evaluation, the permissible range is given as 0.2% proof stress (or yield stress) of aluminum skin divided by a safety factor. 0.2% proof stress depends on aluminum alloy and tempering condition, and the following values are used for ALPOLIC /fr: ALPOLIC /fr Alloy and tempering 0.2% proof stress 3mm, 4mm and 6mm 3105 H14 152 N/mm 2 Generally, panel strength depends on the following factors: (1) Wind load (2) Supporting condition (3) ALPOLIC /fr thickness 10
Guidance for Designing (4) Aluminum skin thickness and 0.2% proof stress (5) ALPOLIC /fr panel size The panel strength can be calculated with the above factors and with several equations, as detailed in White Binder (Technical Brochure of ALPOLIC ). Calculation of panel deflection: Permanent deformation is an ultimate condition and it is indispensable. Panel deflection, on the other hand, belongs to serviceability conditions of the project. If the maximum deflection is specified in the project requirements, we have to confirm whether the expected deflection conforms to the project specifications or not. The calculation method of deflection is also detailed in White Binder (Technical Brochure of ALPOLIC ). The calculated results for 3mm, 4mm and 6mm are attached in Appendix 1. The structural calculation method is outlined in Appendix 2. 1-2. Deforming due to shearing force In those areas where earthquake is possible to hit, the external cladding panel must withstand the shearing force across the panel surface. Appendix 3 is a test result in accordance with JIS A1414 Deforming test of non-bearing wall panel due to shearing force parallel to panel surface. As shown in this test, ALPOLIC /fr panel withstands the shearing force in the displacement range from 1/400 to 1/50. 1-3. Strength of sub-structure Normally, ALPOLIC /fr panels are installed on sub-structure made of steel or aluminum. The sub-structure also must withstand the wind load. The strength of sub-structure depends on the following factors: (1) Rigidity of sub-structure (2) Supporting (anchoring) interval of sub-structure (3) Wind pressure loading on sub-structure Uniformly distributed load Sub-structure As sub-structure is normally deemed as a part of structure, the maximum deflection must meet L/200 rule: the maximum deflection must be smaller than the supporting interval divided by 200 (0.5% of supporting interval). Refer to Appendix 3 for calculation example of sub-structure strength. 1-4. Strength of junction point When suction pressure loads on ALPOLIC /fr panel, the junction hole of rivet or screw must withstand the tension. Otherwise, the junction hole will be torn off and the panel will be removed. Appendix 4 shows how to evaluate the strength of junction hole. Based on this method, the junction interval can be determined. Aluminum profile ALPOLIC /fr In actual installation work, the position of junction hole is important. When the hole is positioned in the proximity of panel edge, its strength will be lessened and may be unsatisfactory. Normally, the distance from hole center to panel edge should be larger than twice of hole diameter. Refer to 11
Guidance for Designing Appendix 4 for further detail. Note: In order to prevent from galvanic corrosion of ALPOLIC /fr, use aluminum or stainless steel rivet, bolt or screw for joining. When ALPOLIC /fr is connected to different metal, lay a coating film 25 microns or thicker on the metal. 2. Thermal expansion The thermal expansion ratio of ALPOLIC /fr is the same as aluminum. Therefore, temperature change will not cause a movement between ALPOLIC /fr and aluminum extrusions. However, because thermal expansion of steel and concrete is smaller, a certain extent of movement is anticipated in long panel between ALPOLIC /fr panels and these structural materials. This movement is normally as small as 1-3mm, but it must be relieved with a suitable method. Thermal expansion & contraction Material Expansion ratio (/ C) Elongation per 1m per 50 C ALPOLIC /fr 24 10-6 1.2mm Aluminum 24 10-6 1.2mm Steel 12 10-6 0.6mm Concrete 12 10-6 0.6mm Acrylic sheet 50-90 10-6 2.5-4.5mm Loose hole Acrylic sheet, on the contrary, has a larger expansion rate. When acrylic sheet is adhered on ALPOLIC panel, the adhesion must permit some movement of acrylic sheet. The drawing indicates an example of loose hole to relieve a possible movement between ALPOLIC /fr panel and sub-structure made of steel. 3. Thermal insulation When ALPOLIC /fr is used for external wall cover, the thermal insulation of overall wall system will be evaluated. The heat transmits by three mechanisms of radiation, convection and conduction. The heat transmission dealt with external wall is a sum composed of these mechanisms. When temperature difference exists between outdoor and indoor atmosphere, the heat flows from the higher temperature to the lower temperature, through the heat transfer from air to wall (I), heat conduction inside the wall (II) and heat transfer from wall to air (III). The overall heat flow process is called heat transmission and expressed with K-value (kcal/m 2 h C) or U-value (W/(m 2 K). Heat Transmission Outdoor Indoor I II III t 1 A o A i t 2 d / C The heat transmission through overall wall system is a sum of each component of wall materials from the outer surface of ALPOLIC /fr to the inner surface of interior. Generally speaking, ALPOLIC /fr panel itself does not have a sufficient thermal insulation effect as an external wall, but the air space 12
Guidance for Designing between ALPOLIC /fr panel and wall material has a recognizable insulation effect. The following table is an example of calculation of total heat transmission. Example of calculated heat transmission through external wall Outdoor 1' 1 2 3 Indoor 4 5 5' 1: ALPOLIC/fr 2: Air space 100mm 3: Brick wall 115mm 4: Air space 50mm 5: Gypsum board 12mm No Component of heat flow Equation Value, kcal/m 2 h C 1' Heat transfer from outer air to ALPOLIC 1/A o 0.05 1 Internal heat conduction in ALPOLIC d 1 /C 1 0.004/0.39=0.01 2 Internal heat transfer in air space d 2 /C 2 0.10 3 Internal heat conduction in brick wall d 3 /C 3 0.115/0.24=0.48 4 Internal heat transfer in air space d 4 /C 4 0.10 5 Internal heat conduction in gypsum board d 5 /C 5 0.012/0.11=0.11 5' Heat transfer from gypsum board to inner air 1/A I 0.13 Total 1/K=1/A o +Σd i /C i +1/A i 1/K=0.98 K=1.02 kcal/m 2 h C (U=1.19 W/(m 2 K) K-value: Heat transmission (kcal/m 2 h) A o, i : Heat transfer coefficients (kcal/m 2 h C) C: Heat conductivity (kcal/mh C) d: Wall thickness (m) Note: K-value is also called U-value in SI unit in ISO, and converted by K-value (kcal/m 2 h)=0.86 U-value (W/(m 2 K)). Refer to Appendix 5 for further details. 4. Waterproofing In order to ensure waterproofing of joints between panels, normally, a sealing material is used for joints. The sealing material shall meet the performance required for the project and also it must be compatible with ALPOLIC /fr panel. Silicone, modified silicone, polysulfide and polyurethane sealant are used for exterior. Among these materials, silicone sealant is the best in weatherability, but, as widely known, it stains panel surface. Recently, sealant manufacturers developed less staining type of silicone, in which the disadvantage of staining is considerably improved. Refer to Appendix 6 for general comparison among sealing materials. Regarding the joint design such as joint width and thickness, please follow the sealant manufacturer s specifications. Actual sealing work at site is also important. Improper work will affect not only the aesthetic appearance of installed panel but also the waterproofing performance of the joint. Therefore, the sealing work must be conducted carefully, based on the instructions from sealant manufacturers. For the typical sealing procedures, refer to Fabrication and Installation. 13
Guidance for Designing When rubber gasket is used for joint, the waterproofing will not be perfect, taking its long-term durability into consideration. Therefore, a secondary-waterproofing device may be provided behind joint to ensure the perfect waterproofing. 5. Panel layout and special panel detail (1) Coating direction of Metallic Colors and Sparkling Colors In case of Metallic Colors and Sparkling Colors, there is a slight color difference between standing vertically (like portrait) and horizontally (like landscape) due to the coating direction. This slight color difference is subtle but perceptible from some angle after installation. Therefore, in case of traverse and parallel coating directions are co-existing in an area, the color difference must be carefully checked in advance. In the shown example, it is likely that the color difference between Panel A and B is perceptible from some angle in case of Metallic and Sparkling Colors. Panel A Panel B Window Coating direction Panel A Stone Series requires the similar attention, because it consists of small grain pattern with directional arrangement. The similar check is necessary for Stone Series in advance. In case of Solid Colors (No-metallic Colors), the above color difference is negligible. Solid Color panels can be laid out with different coating direction. It is because of the smoother and the finer coating of ALPOLIC /fr derived from Die Coating. (2) Bending limit There are two types of bending methods: by press brake and by 3-roll bender. By means of press brake, the minimum bendable limit of ALPOLIC /fr is about 80-100 mm in radius. By means of 3-roll bender, it is 250 to 300 mm in radius, depending on the diameter of the bending roll. Please refer to Fabrication and Installation for details. (3) Special panel detail Special shaped panels such as 3-dimension panels and combined panels are often required. Whenever we face to such complicated panels, we have to study how to embody the shape without degrading the advantages of ALPOLIC /fr. Sometimes we have to ask some modification on the original design for compromise. Several types of these panels are shown in Fabrication and Installation. 6. Lightning In the event that a lightning should strike ALPOLIC /fr panel instead of lightning rod, what will happen on the panel and the building. When the aluminum skin is connected to the ground earth, the electricity will be discharged to the ground earth and nothing will happen in the vicinity of the struck panel, although the struck panel itself might be damaged with the enormous magnitude of lightning impact. Refer to Appendix 7 for further details. 14
Guidance for Designing Appendix 1 Structural strength of ALPOLIC /fr The maximum stress exerting in aluminium skin of ALPOLIC/fr can be calculated with the following equation: Stress = B w b 2 / t 2 Where, b: panel width or height, whichever shorter side B: coefficient dependent on a/b ratio (panel width/panel height) and supporting condition, as shown in White Binder P. 10. w: wind pressure (N/mm 2 or 10-6 N/m 2 or 10-3 kpa) t 2 : square of apparent thickness of ALPOLIC, given in the following table: The relevant values to ALPOLIC /fr 3mm, 4mm and 6mm are given as follows: ALPOLIC /fr t 2 (mm 2 ) 0.2% proof stress 3mm 6.33 152 N/ mm 2 4mm 9.25 152 N/ mm 2 6mm 15.17 152 N/ mm 2 When the maximum stress calculated with the above equation does not exceed 0.2% proof stress (yield stress), aluminium skins are still within elastic range and permanent deformation will not occur. Note: Regarding details of the above calculation method, refer to White Binder, in which structural calculation methods are explained for general purpose. The maximum deflection of ALPOLIC/fr panel, on the other hand, can be calculated with the following equation: Deflection = A w b 4 / E AP t AP 3 Where, b: panel width or height, whichever shorter side A: coefficient dependent on a/b ratio (panel width/panel height) and supporting condition, as shown in White Binder P. 12. w: wind pressure (N/mm 2 or 10-6 N/m 2 or 10-3 kpa) E AP: flexural elastic modulus of ALPOLIC/fr t AP : thickness of ALPOLIC/fr E AP t AP 3 values are given as follows: ALPOLIC /fr E AP (N/mm 2 ) 3 E AP t AP (N mm) 3mm 49000 1323 10 3 4mm 39800 2546 10 3 6mm 29100 6287 10 3 Tables 1-6 are the calculated results for ALPOLIC/fr 3mm, 4mm and 6mm. The condition marked with > indicates that the maximum stress exceeds 0.2% proof stress (yield stress) of aluminum skin 3105-H14 (152 N/mm 2 ). Stiffener will be required in this condition. In other range, where the 15
Guidance for Designing Appendix 1 calculated stress is lower than 152 N/mm 2, the panel will withstand the condition without stiffener. ALPOLIC /fr thickness Supporting condition Table 1 4mm 4-side fixed Table 2 4mm 4-side simply supported Table 3 6mm 4-side fixed Table 4 6mm 4-side simply supported Table 5 3mm 4-side fixed Table 6 3mm 4-side simply supported If you require other cases, which is not shown in the tables, please inquire to our office. We will provide separate calculation reports. 16
Guidance for Designing Appendix 1 Table 1. ALPOLIC /fr 4mm, 4-side fixed Premise Thickness: Supporting condition: Stiffener: ALPOLIC/fr 4mm 4-side fixed None Maximum stress (N/mm 2 ) w, kpa Panel width Panel length (a, mm) (kg/m 2 ) (b, mm) 900 1200 1500 1800 2100 2400 2700 3000 >3000 1.0 600 18 19 19 19 19 19 19 19 19 (102) 900 27 37 42 44 44 44 44 44 44 1200 37 48 62 70 75 77 78 78 78 1500 42 62 75 93 106 114 119 121 122 1.5 600 26 29 29 29 29 29 29 29 29 (153) 900 40 55 62 65 66 66 66 66 66 1200 55 72 93 106 113 116 117 117 117 1500 62 93 112 140 159 > 171 > 178 > 181 > 182 > 2.0 600 35 39 39 39 39 39 39 39 39 (204) 900 54 73 83 87 88 88 88 88 88 1200 73 96 123 141 150 155 > 156 > 156 > 156 > 1500 83 123 150 187 > 212 > 228 > 237 > 242 > 243 > 2.5 600 44 48 49 49 49 49 49 49 49 (255) 900 67 91 104 109 109 109 109 109 109 1200 91 120 154 > 176 > 188 > 194 > 195 > 195 > 195 > 1500 104 154 > 187 > 233 > 265 > 285 > 296 > 302 > 304 > 3.0 600 53 58 58 58 58 58 58 58 58 (306) 900 81 110 125 131 131 131 131 131 131 1200 110 144 185 > 211 > 225 > 232 > 234 > 234 > 234 > 1500 125 185 > 225 > 280 > 318 > 342 > 356 > 363 > 365 > Note: > indicates that the maximum stress exceeds 0.2% proof stress (yield stress) of aluminum skin 3105 H14 (152 N/mm 2 ). Stiffener will be required in this range. Maximum deflection (mm) w, kpa Panel width Panel length (a, mm) (kg/m2) (b, mm) 900 1200 1500 1800 2100 2400 2700 3000 >3000 1.0 600 1 1 1 1 1 1 1 1 1 (102) 900 4 5 7 7 7 7 7 7 7 1200 6 11 16 19 21 23 23 23 23 1500 7 16 27 37 45 50 53 55 56 1.5 600 2 2 2 2 2 2 2 2 2 (153) 900 5 8 10 11 11 11 11 11 11 1200 8 17 24 29 32 34 35 35 35 1500 10 24 41 56 NA > NA > NA > NA > NA > 2.0 600 2 3 3 3 3 3 3 3 3 (204) 900 7 11 13 14 15 15 15 15 15 1200 11 22 32 39 43 NA > NA > NA > NA > 1500 13 32 55 NA > NA > NA > NA > NA > NA > 2.5 600 3 4 4 4 4 4 4 4 4 (255) 900 9 14 16 18 18 18 18 18 18 1200 14 28 NA > NA > NA > NA > NA > NA > NA > 1500 16 NA > NA > NA > NA > NA > NA > NA > NA > 3.0 600 4 4 4 4 4 4 4 4 4 (306) 900 11 16 20 21 22 22 22 22 22 1200 17 34 NA > NA > NA > NA > NA > NA > NA > 1500 20 NA > NA > NA > NA > NA > NA > NA > NA > 17
Guidance for Designing Appendix 1 Table 2. ALPOLIC /fr 4mm, 4-side simply supported Premise Thickness: Supporting condition: Stiffener: ALPOLIC/fr 4mm 4-side simply supported None Maximum stress (N/mm 2 ) w, kpa Panel width Panel length (a, mm) (kg/m2) (b, mm) 900 1200 1500 1800 2100 2400 2700 3000 >3000 1.0 600 19 24 26 28 29 29 29 29 29 (102) 900 25 37 47 53 56 59 62 66 66 1200 37 45 62 76 87 95 99 103 117 1500 47 62 70 92 110 126 138 148 182 > 1.5 600 28 36 39 42 44 44 44 44 44 (153) 900 38 56 70 80 85 89 94 99 99 1200 56 67 92 113 130 142 149 155 > 175 > 1500 70 92 105 137 165 > 189 > 208 > 223 > 274 > 2.0 600 38 47 52 56 58 58 58 58 58 (204) 900 50 75 94 107 113 119 125 131 131 1200 75 89 123 151 173 > 190 > 198 > 206 > 234 > 1500 94 123 140 183 > 220 > 252 > 277 > 297 > 365 > 2.5 600 47 59 64 69 73 73 73 73 73 (255) 900 63 93 117 134 141 149 156 > 164 > 164 > 1200 93 112 154 > 189 > 216 > 237 > 248 > 258 > 292 > 1500 117 154 > 175 > 229 > 275 > 315 > 346 > 371 > 456 > 3.0 600 57 71 77 83 88 88 88 88 88 (306) 900 76 112 141 160 > 169 > 178 > 187 > 197 > 197 > 1200 112 134 185 > 227 > 260 > 285 > 297 > 309 > 350 > 1500 141 185 > 210 > 275 > 331 > 377 > 415 > 445 > 547 > Note: > indicates that the maximum stress exceeds 0.2% proof stress (yield stress) of aluminum skin 3105 H14 (152 N/mm 2 ). Stiffener will be required in this range. Maximum deflection (mm) w, kpa Panel width Panel length (a, mm) (kg/m2) (b, mm) 900 1200 1500 1800 2100 2400 2700 3000 >3000 1.0 600 4 6 6 7 7 7 7 7 7 (102) 900 11 19 24 29 31 32 34 37 37 1200 18 36 54 68 81 90 95 100 109 1500 24 54 87 123 153 180 202 221 NA > 1.5 600 6 8 9 10 11 11 11 11 11 (153) 900 17 28 37 43 46 49 52 55 55 1200 28 54 80 102 121 136 142 NA > NA > 1500 37 80 131 185 NA > NA > NA > NA > NA > 2.0 600 9 11 12 14 14 14 14 14 14 (204) 900 23 37 49 57 61 65 69 73 73 1200 37 72 107 137 NA > NA > NA > NA > NA > 1500 49 107 175 NA > NA > NA > NA > NA > NA > 2.5 600 11 14 16 17 18 18 18 18 18 (255) 900 28 46 61 72 76 81 NA > NA > NA > 1200 46 90 NA > NA > NA > NA > NA > NA > NA > 1500 61 NA > NA > NA > NA > NA > NA > NA > NA > 3.0 600 13 17 19 20 22 22 22 22 22 (306) 900 34 56 73 NA > NA > NA > NA > NA > NA > 1200 55 108 NA > NA > NA > NA > NA > NA > NA > 1500 73 NA > NA > NA > NA > NA > NA > NA > NA > 18
Guidance for Designing Appendix 1 Table 3. ALPOLIC /fr 6mm, 4-side fixed Premise Thickness: Supporting condition: Stiffener: ALPOLIC/fr 6mm 4-side fixed None Maximum stress (N/mm 2 ) w, kpa Panel width Panel length (a, mm) (kg/m2) (b, mm) 900 1200 1500 1800 2100 2400 2700 3000 >3000 1.0 600 11 12 12 12 12 12 12 12 12 (102) 900 16 22 25 27 27 27 27 27 27 1200 22 29 38 43 46 47 47 47 47 1500 25 38 46 57 65 69 72 74 74 1.5 600 16 18 18 18 18 18 18 18 18 (153) 900 25 33 38 40 40 40 40 40 40 1200 33 44 56 64 69 71 71 71 71 1500 38 56 68 85 97 104 108 111 111 2.0 600 21 24 24 24 24 24 24 24 24 (204) 900 33 45 51 53 53 53 53 53 53 1200 45 58 75 86 92 94 95 95 95 1500 51 75 91 114 129 139 145 148 148 2.5 600 27 30 30 30 30 30 30 30 30 (255) 900 41 56 63 66 67 67 67 67 67 1200 56 73 94 107 114 118 119 119 119 1500 63 94 114 142 162 > 174 > 181 > 184 > 185 > 3.0 600 32 35 36 36 36 36 36 36 36 (306) 900 49 67 76 80 80 80 80 80 80 1200 67 88 113 129 137 142 142 142 142 1500 76 113 137 171 > 194 > 208 > 217 > 221 > 222 > Note: > indicates that the maximum stress exceeds 0.2% proof stress (yield stress) of aluminum skin 3105 H14 (152 N/mm 2 ). Stiffener will be required in this range. Maximum deflection (mm) w, kpa Panel width Panel length (a, mm) (kg/m2) (b, mm) 900 1200 1500 1800 2100 2400 2700 3000 >3000 1.0 600 0 1 1 1 1 1 1 1 1 (102) 900 1 2 3 3 3 3 3 3 3 1200 2 5 7 8 9 9 9 9 9 1500 3 7 11 15 18 20 21 22 23 1.5 600 1 1 1 1 1 1 1 1 1 (153) 900 2 3 4 4 4 4 4 4 4 1200 3 7 10 12 13 14 14 14 14 1500 4 10 17 23 27 30 32 33 34 2.0 600 1 1 1 1 1 1 1 1 1 (204) 900 3 4 5 6 6 6 6 6 6 1200 4 9 13 16 17 18 19 19 19 1500 5 13 22 30 36 40 43 45 46 2.5 600 1 1 1 1 1 1 1 1 1 (255) 900 4 6 7 7 7 7 7 7 7 1200 6 11 16 20 22 23 23 23 23 1500 7 16 28 38 NA > NA > NA > NA > NA > 3.0 600 1 2 2 2 2 2 2 2 2 (306) 900 4 7 8 9 9 9 9 9 9 1200 7 14 20 24 26 27 28 28 28 1500 8 20 33 NA > NA > NA > NA > NA > NA > 19
Guidance for Designing Appendix 1 Table 4. ALPOLIC /fr 6mm, 4-side simply supported Premise Thickness: Supporting condition: Stiffener: ALPOLIC/fr 6mm 4-side simply supported None Maximum stress (N/mm 2 ) w, kpa Panel width Panel length (a, mm) (kg/m2) (b, mm) 900 1200 1500 1800 2100 2400 2700 3000 >3000 1.0 600 12 14 16 17 18 18 18 18 18 (102) 900 15 23 29 33 34 36 38 40 40 1200 23 27 38 46 53 58 60 63 71 1500 29 38 43 56 67 77 84 91 111 1.5 600 17 22 24 25 27 27 27 27 27 (153) 900 23 34 43 49 52 54 57 60 60 1200 34 41 56 69 79 87 91 94 107 1500 43 56 64 84 101 115 127 136 167 > 2.0 600 23 29 31 34 36 36 36 36 36 (204) 900 31 46 57 65 69 73 76 80 80 1200 46 55 75 92 106 116 121 126 142 1500 57 75 85 112 134 153 > 169 > 181 > 222 > 2.5 600 29 36 39 42 44 44 44 44 44 (255) 900 38 57 71 81 86 91 95 100 100 1200 57 68 94 115 132 145 151 157 > 178 > 1500 71 94 107 139 168 > 192 > 211 > 226 > 278 > 3.0 600 35 43 47 51 53 53 53 53 53 (306) 900 46 68 86 98 103 109 114 120 120 1200 68 82 113 138 158 > 174 > 181 > 188 > 214 > 1500 86 113 128 167 > 202 > 230 > 253 > 272 > 334 > Note: > indicates that the maximum stress exceeds 0.2% proof stress (yield stress) of aluminum skin 3105 H14 (152 N/mm 2 ). Stiffener will be required in this range. Maximum deflection (mm) w, kpa Panel width Panel length (a, mm) (kg/m2) (b, mm) 900 1200 1500 1800 2100 2400 2700 3000 >3000 1.0 600 2 2 3 3 3 3 3 3 3 (102) 900 5 7 10 12 12 13 14 15 15 1200 7 15 22 28 33 37 38 40 44 1500 10 22 35 50 62 73 82 89 107 1.5 600 3 3 4 4 4 4 4 4 4 (153) 900 7 11 15 17 19 20 21 22 22 1200 11 22 33 41 49 55 58 61 66 1500 15 33 53 75 93 109 123 134 NA > 2.0 600 3 5 5 6 6 6 6 6 6 (204) 900 9 15 20 23 25 26 28 30 30 1200 15 29 43 55 65 73 77 81 88 1500 20 43 71 100 124 NA > NA > NA > NA > 2.5 600 4 6 6 7 7 7 7 7 7 (255) 900 11 19 25 29 31 33 35 37 37 1200 19 36 54 69 82 92 96 NA > NA > 1500 25 54 89 125 NA > NA > NA > NA > NA > 3.0 600 5 7 8 8 9 9 9 9 9 (306) 900 14 22 30 35 37 39 42 45 45 1200 22 44 65 83 NA > NA > NA > NA > NA > 1500 30 65 106 NA > NA > NA > NA > NA > NA > 20
Guidance for Designing Appendix 1 Table 5. ALPOLIC /fr 3mm, 4-side fixed Premise Thickness: Supporting condition: Stiffener: ALPOLIC/fr 3mm 4-side fixed None Maximum stress (N/mm 2 ) w, kpa Panel width Panel length (a, mm) (kg/m2) (b, mm) 900 1200 1500 1800 2100 2400 2700 3000 >3000 1.0 600 26 28 28 28 28 28 28 28 28 (102) 900 39 53 61 64 64 64 64 64 64 1200 53 70 90 103 110 113 114 114 114 1500 61 90 109 136 155 > 166 > 173 > 177 > 178 > 1.5 600 39 42 43 43 43 43 43 43 43 (153) 900 59 80 91 95 96 96 96 96 96 1200 80 105 135 154 > 165 > 170 > 171 > 171 > 171 > 1500 91 135 164 > 204 > 232 > 250 > 260 > 265 > 267 > 2.0 600 51 57 57 57 57 57 57 57 57 (204) 900 79 107 121 127 128 128 128 128 128 1200 107 140 180 > 206 > 219 > 226 > 227 > 227 > 227 > 1500 121 180 > 219 > 273 > 310 > 333 > 346 > 354 > 355 > Note: > indicates that the maximum stress exceeds 0.2% proof stress (yield stress) of aluminum skin 3105 H14 (152 N/mm 2 ). Stiffener will be required in this range. Maximum deflection (mm) w, kpa Panel width Panel length (a, mm) (kg/m2) (b, mm) 900 1200 1500 1800 2100 2400 2700 3000 >3000 1.0 600 2 3 3 3 3 3 3 3 3 (102) 900 7 11 13 14 14 14 14 14 14 1200 11 22 31 37 41 43 45 45 45 1500 13 31 53 72 NA > NA > NA > NA > NA > 1.5 600 4 4 4 4 4 4 4 4 4 (153) 900 10 16 19 21 21 21 21 21 21 1200 16 32 47 NA > NA > NA > NA > NA > NA > 1500 19 47 NA > NA > NA > NA > NA > NA > NA > 2.0 600 5 5 6 6 6 6 6 6 6 (204) 900 14 21 25 27 28 28 28 28 28 1200 21 43 NA > NA > NA > NA > NA > NA > NA > 1500 25 NA > NA > NA > NA > NA > NA > NA > NA > 21
Guidance for Designing Appendix 1 Table 6. ALPOLIC /fr 3mm, 4-side simply supported Premise Thickness: Supporting condition: Stiffener: ALPOLIC/fr 3mm 4-side simply supported None Maximum stress (N/mm 2 ) w, kpa Panel width Panel length (a, mm) (kg/m2) (b, mm) 900 1200 1500 1800 2100 2400 2700 3000 >3000 1.0 600 28 35 38 41 43 43 43 43 43 (102) 900 37 55 68 78 82 87 91 96 96 1200 55 65 90 110 126 139 145 151 171 < 1500 68 90 102 134 161 < 184 < 202 < 217 < 267 < 1.5 600 41 52 56 61 64 64 64 64 64 (153) 900 55 82 103 117 124 130 137 144 144 1200 82 98 135 166 < 190 < 208 < 217 < 226 < 256 < 1500 103 135 153 < 201 < 242 < 276 < 303 < 325 < 400 < 2.0 600 55 69 75 81 85 85 85 85 85 (204) 900 74 109 137 156 < 165 < 174 < 183 < 192 < 192 < 1200 109 131 180 < 221 < 253 < 278 < 289 < 301 < 341 < 1500 137 180 < 204 < 267 < 322 < 368 < 404 < 434 < 533 < Note: > indicates that the maximum stress exceeds 0.2% proof stress (yield stress) of aluminum skin 3105 H14 (152 N/mm 2 ). Stiffener will be required in this range. Maximum deflection (mm) w, kpa Panel width Panel length (a, mm) (kg/m2) (b, mm) 900 1200 1500 1800 2100 2400 2700 3000 >3000 1.0 600 8 11 12 13 14 14 14 14 14 (102) 900 22 36 47 55 59 63 66 71 71 1200 36 69 103 131 155 174 183 192 209 1500 47 103 168 237 NA < NA < NA < NA < NA < 1.5 600 12 16 18 20 21 21 21 21 21 (153) 900 33 53 70 83 88 94 99 106 106 1200 53 103 155 NA < NA < NA < NA < NA < NA < 1500 70 155 NA < NA < NA < NA < NA < NA < NA < 2.0 600 16 22 24 26 28 28 28 28 28 (204) 900 44 71 94 NA < NA < NA < NA < NA < NA < 1200 71 138 NA < NA < NA < NA < NA < NA < NA < 1500 94 NA < NA < NA < NA < NA < NA < NA < NA < 22
Guidance for Designing Appendix 2 Structural calculation method of ALPOLIC /fr panel 1. Structural calculation without stiffener (1) How to calculate the maximum stress When wind pressure is working on ALPOLIC/fr panel, the panel shows some deflection. Simultaneously, some intensity of stress arises in the panel in order to withstand the bending force. Strength design of ALPOLIC/fr assumes that bending strength of ALPOLIC/fr panel totally depends on aluminium skins. As far as the stress exerting in aluminium skin is lower than the permissible stress (0.2% proof stress or yield stress) of aluminum skin, the panel is still elastic. Therefore, we confirm whether the stress is lower or larger than the permissible stress. This can be expressed with the following equation: Stress M < Stress Y Where, Stress M : Maximum stress in aluminum skin (N/mm 2 or kg/mm 2 ) Stress Y : 0.2% proof stress (yield stress) of aluminum skin (N/mm 2 or kg/mm 2 ) b Stress a Aluminum skin Core material Aluminum skin The 0.2% proof stress (yield stress) depends on aluminum material and its tempering condition. In case of ALPOLIC (3105 H14), the following value is used: Stress Y =152 Ng/mm 2 (=15.5 kg/mm 2 ) The maximum stress exerting in aluminium sheet, depending on the support condition and panel size, can be calculated with the following equation: Stress M = B w b 2 / t 2 Where, b: Panel width or height, whichever shorter side B: Coefficient dependent on a/b ratio (panel width/panel height) w: Wind pressure (kpa, kn/ m 2 or kg/m 2 ) t 2 : Square of apparent thickness of ALPOLIC/fr, given in the following table: ALPOLIC/fr t 2 (mm 2 ) 3 mm 6.33 4 mm 9.25 6 mm 15.17 (2) Calculation example of maximum stress A. Premise 23
Guidance for Designing Appendix 2 Wind load: 1.5 kpa (1.5 kn/m 2 = 153 kg/m 2 ) ALPOLIC/fr thickness: 4 mm Panel size: 1220 2440 mm Supporting condition: 4-side fixed B. Result Stress M = B w b 2 / t 2 Where, a/b=2.0, then B=0.4974 (from Table 1 or White Binder P.10) Stress M = 0.4974 1500 10-6 1220 2 / 9.25 = 120 < 152 N/mm 2 Therefore, the panel will withstand the above condition including safety factor 1.26. (2) How to calculate deflection The deflection of ALPOLIC/fr panel can be calculated with the following equation: Deflection = A w b 4 / (E AP t 3 AP ) Where, Deflection: Maximum deflection of ALPOLIC panel b: Panel width or height, whichever shorter side A: Coefficient dependent on a/b ratio (length/width) w: Wind pressure (kpa, kn/ m 2 or kg/m 2 ) E AP : Bending elastic modulus of ALPOLIC/fr (N/mm 2 or kg/mm 2 ) t AP : Thickness of ALPOLIC/fr (mm) 3 E AP t AP is given in the following table: ALPOLIC/fr E AP t 3 AP (N mm) E AP t 3 AP (kg mm) 3 mm 1323 10 3 135.0 10 3 4 mm 2546 10 3 259.8 10 3 6 mm 6287 10 3 641.5 10 3 Deflection (4) Calculation example of deflection A. Premise Wind load: 1.5 kpa (1.5 kn/m 2 = 153 kg/m 2 ) ALPOLIC/fr thickness: 4 mm Panel size: 1220 2440 mm Supporting condition: 4-side fixed B. Result Deflection = A w b 4 / (E AP t AP 3 ) Where, a/b=2.0, then A = 0.0277 (from Table 2 or White Binder P.12) Deflection = 0.0277 1500 10-6 1220 4 / (2546 10 3 ) = 36 mm 2. Strength design reinforced with stiffener As a result of the above calculation, when the maximum stress exceeds the permissible stress of aluminium skin, or when the maximum deflection exceeds the project requirement, we will study to 24
Guidance for Designing Appendix 2 reinforce the panel with stiffener as one of the alternative solutions. In this study, we select a stiffener and evaluate whether the stiffener withstands the given condition or not. The rigidity of typical stiffeners are summarised in Table 3. (1) How to calculate stress The bending moment over the area B is given with the following equation: a M = W a 2 / 8 (N mm) Where, W: Wind pressure loaded on the area B W = w B (w : uniform distributed load, N/mm 2 ) b B Stiffener This bending moment is shared by stiffener and ALPOLIC/fr panel respectively as follows: Stiffener: M 1 = M I 1 / (I 1 + I 2 ) ALPOLIC/fr: M 2 = M I 2 / (I 1 + I 2 ) Where, I 1 : Moment of inertia of stiffener (refer to Table 3) I 2 : Moment of inertia of ALPOLIC/fr, given with the following equation: I 2 = B (H 3 h 3 ) / 12 (mm 4 ) B: Length of the area B (mm) H: ALPOLIC/fr thickness (mm) h: Thickness of core material, or internal span between aluminium skin sheets (mm) Then, the bending stress is given with the following equation: Stress 1 = M 1 / Z 1 Stress 2 = M 2 / Z 2 (Stress in stiffener) (Stress in ALPOLIC/fr) Where, Z 1 : Section modulus of stiffener (refer to Table 3) Z 2 : Section modulus of ALPOLIC/fr, given with the following equation: Z 2 = B (H 3 h 3 ) / 6H (mm 3 ) Permanent deformation will not occur within the following range: Stress 1 < Stress 1Y (for Stiffener) Stress 2 < Stress 2Y (for ALPOLIC/fr) Where, Stress 1Y : 0.2% proof stress (yield stress) of stiffener (refer to Table 3) Stress ey : 0.2% proof stress (yield stress) of aluminium skin of ALPOLIC/fr (152 N/mm 2 ) (2) Calculation example of stress A. Premise 25
Guidance for Designing Appendix 2 Wind load: 2.5 kpa (=2.5 kn/m 2 = 255 kg/m 2 ) ALPOLIC/fr thickness: 4 mm Panel size: 1220 2440 mm Supporting condition: 4-side fixed Stiffener: 50 25 2.5mm t, aluminium extrusion (A6063, T5), 2 pieces per panel 50 2440 813 2.5 25 1220 B. Moment of inertia and section modulus Stiffener: I 1 = 3.51 10 4 mm 4 Z 1 = 2.81 10 3 mm 3 ALPOLIC/fr: I 2 = B (H 3 h 3 ) / 12 = 813 (4 3-3 3 ) / 12 = 0.25 10 4 mm 4 Z 2 = B (H 3 h 3 ) / 6H = 813 (4 3-3 3 ) / 24 = 1.25 10 3 mm 3 Stiffener+ALPOLIC/fr: ΣI = I 1 + I 2 = 3.76 10 4 mm 4 C. Calculation of stress Bending moment: M = W a 2 / 8 = 2500 10-6 813 1220 2 / 8 = 37.81 10 4 N mm Stiffener s share: M 1 = M I 1 / (I 1 + I 2 ) = 37.81 10 4 3.51 / 3.76 = 35.30 10 4 ALPOLIC/fr s share: M 2 = M I 2 / (I 1 + I 2 ) = 37.81 10 4 0.25/ 3.76 = 2.51 10 4 Bending stress: Stress 1 = M 1 / Z 1 = 35.30 10 4 / 2.81 10 3 = 126 < 147 N/mm 2 (OK) Stress 2 = M 2 / Z 2 = 2.51 10 4 / 1.25 10 3 = 20 < 152 N/mm 2 (OK) Therefore, the panel will withstand the above conditions including safety factor 1.17 for stiffener. (3) How to calculate deflection As for the deflection, respective deflection of stiffener and ALPOLIC is calculated first, and then the total deflection is given as a combined sum. Deflection of stiffener: Deflection 1 = 5 W a 4 / 384 E 1 I 1 (mm) 26
Guidance for Designing Appendix 2 Where, E 1 : Elastic modulus of stiffener (=70000 N/mm 2 ) Deflection of ALPOLIC/fr: Deflection 2 = A w b 4 / (E AP t AP 3 ) (mm) Combined deflection can be calculated with the following equation: Deflection = Deflection 1 Deflection 2 / (Deflection 1 + Deflection 2 ) (mm) (4) Calculation example of deflection A. Premise (the same conditions as above) Wind load: 2.5 kpa (=2.5 kn/m 2 = 255 kg/m 2 ) ALPOLIC/fr thickness: 4 mm Panel size: 1220 2440 mm Supporting condition: 4-side fixed Stiffener: 50 25 2.5mm t, aluminium extrusion (A6063, T5), 2 pieces per panel B. Deflection Deflection of stiffener: Deflection 1 = 5 W a 4 / 384 E 1 I 1 = 5 3000 10-6 813 1220 4 / (384 70000 3.51 10 4 ) = 28.6 mm Deflection of ALPOLIC: Deflection 2 = A w b 4 / (E AP t AP 3 ) Where, a/b=1220/813=1.50, then A=0.0838 (from Table 2 or White Binder P.12) Deflection 2 = 0.0838 3000 10-6 813 4 / (2546 10 3 ) = 43.1 mm Combined deflection: Deflection = Deflection 1 Deflection 2 / (Deflection 1 + Deflection 2 ) = 28.6 43.1 / (28.6+43.1) = 17.2 mm 27
Guidance for Designing Appendix 2 Table 1 Coefficient B for calculation of stress Support condition 2-side simply supported and 2-side free b Equation and B value Stress M = 0.75 w b 2 / t 2 2-side fixed and 2-side free b Stress M = 0.5 w b 2 / t 2 4-side simply supported a b Stress M = B w b 2 / t 2 a/b 1 1.2 1.4 1.6 1.8 2.0 3.0 4-side fixed a b B 0.2874 0.3762 0.4530 0.5172 0.5688 0.6102 0.7134 Stress M = B w b 2 / t 2 a/b 1 1.2 1.4 1.6 1.8 2.0 >2.0 B 0.3078 0.3834 0.4356 0.4680 0.4872 0.4974 0.5000 Note: The above is an excerpt from White Binder P.10. Refer to White Binder for other cases. Table 2 Coefficient A for calculation of deflection Support condition 2-side simply supported and 2-side free b Equation and A value Deflection = 0.156 w b 4 / (E AP t AP 3 ) 2-side fixed and 2-side free b Deflection = 0.0313 w b 4 / (E AP t AP 3 ) 4-side simply supported a b Deflection = A w b 4 / (E AP t AP 3 ) a/b 1 1.2 1.4 1.6 1.8 2.0 3.0 >3.0 4-side fixed a b A 0.044 0.062 0.077 0.0906 0.1017 0.1110 0.1335 0.1422 Deflection = A w b 4 / (E AP t AP 3 ) a/b 1 1.2 1.4 1.6 1.8 2.0 >2.0 A 0.0138 0.0188 0.0226 0.0251 0.0267 0.0277 0.0284 Note: The above is an excerpt from White Binder P.12. Refer to White Binder for other cases. 28
Guidance for Designing Appendix 2 Table 3. Rigidity of Various Stiffeners Aluminium extrusion 40 20 2.0mmt 6063S-T5 Stiffener / Material (Unit weight) 20 40 2.0t Moment of inertia (I X, mm 4 ) Section modulus (Z X, mm 3 ) 0.2% proof stress (N/mm 2 ) I X = 1.44 10 4 Z X = 1.44 10 3 147 N/mm 2 (640g/m) Aluminium extrusion 50 25 1.5mmt 6063S-T5 25 50 1.5t I X = 2.34 10 4 Z X = 1.87 10 3 147 N/mm 2 (600g/m) Aluminium extrusion 50 25 2.0mmt 6063S-T5 25 50 2.0t I X = 2.96 10 4 Z X = 2.36 10 3 147 N/mm 2 (800g/m) Aluminium extrusion 50 25 2.5mmt 6063S-T5 25 50 2.5t I X = 3.51 10 4 Z X = 2.81 10 3 147 N/mm 2 (1000g/m) Aluminium extrusion 40 20 2.0t 6063S-T5 40 20 2.0t I X = 4.45 10 4 Z X = 2.22 10 3 147 N/mm 2 (640g/m) Aluminium extrusion 50 25 1.5t 6063S-T5 50 25 1.5t I X = 7.01 10 4 Z X = 2.80 10 3 147 N/mm 2 (600g/m) Aluminium extrusion 50 25 2.0t 6063S-T5 50 25 2.0t I X = 9.01 10 4 Z X = 3.60 10 3 147 N/mm 2 (800g/m) Aluminium extrusion 50 25 2.5t 6063S-T5 50 25 2.5t I X = 10.85 10 4 Z X = 4.34 10 3 147 N/mm 2 (1000g/m) Aluminum sheet 60 30 3.0t 1100-H24 30 60 3.0 I X = 2.80 10 4 Z X = 1.35 10 3 118 N/mm 2 (970g/m) 29
Guidance for Designing Appendix 2 Fig. 1 Fixation method of stiffener ALPOLIC/fr panel reinforced with stiffener - from reverse side Stiffener Example A Aluminum m angle Rivet Stiffener Aluminum flange VHB tape Example B 30
Guidance for Designing Appendix 3 Deforming test due to shearing force parallel to panel surface 1. Test method The test was held in accordance with JIS A1414 Deforming test of non-bearing wall panel due to shearing force parallel to panel surface. (1) Specimen 1150 2300 Tray type panel (Panel depth: 30mm) Material: ALPOLIC 4mm Fig. 1 Test apparatus (2) Test apparatus The test apparatus is shown in Fig. 1. The specimen is fixed onto L30 30 3mm angle of the holder with tapping screw. Bolt M16 is equipped at one corner to apply a shearing force parallel to the panel surface. (3) Test method Tighten the bolt M16 until the measurement point D1 reaches P 1 =1/400, P 2 =1/300, P 3 =1/200, P 4 =1/150, P 5 =1/100, P 6 =1/75 and P 7 =1/50. P shows a ratio of horizontal displacement to panel height. Observe the following items: A: Deformation and remaining deflection of the specimen and fixing points. B: Noise of breakage C: Peel-off or de-lamination of finishing material. D: Crack or gap penetrating the panel and fixation points. 31
Guidance for Designing Appendix 3 2. Test result (1) Displacement and panel deflection Displacement ratio (P) Initial 1/400 1/300 1/200 1/150 1/100 1/75 1/50 Displacement (mm) D1 0 6 8 11 16 23 31 46 D2-0 0 0 0 0 0 0 D3 - -1-2 -1-1 -1-2 -1 D4 - -3-4 -5-6 -9-11 -16 D5-0 0 1 1 3 4 6 Deflection (mm) A - 0 0 0 0 0 0.8 1.0 B - 0 0 0 0 0 0.5 0.5 C - 0 0 0 0.5 0.5 2.0 3.0 Note: The positions of measurement points are shown in Fig. 2. (2) Observation during and after the test The panel, flange and fixation point with tapping screw was normal during and after the test. The displacement was absorbed in the panel deflection, which was completely restored to the original position when the displacement was eliminated after the test. Any problem was not observed in other assemblies of the tray type panel. Fig. 2, Measurement points 32
Guidance for Designing Appendix 4 Strength of sub-structure 1. Calculation method For structural calculation, sub-structure can be handled as a beam, on which wind load is uniformly distributed. Normally, sub-structure is deemed as a part of structure, and so L/200 rule (L: supporting interval of sub-structure) is applied on the deflection of sub-structure. Therefore, sub-structure must meet two conditions: (1) Maximum stress not to exceed the permissible stress (2) Maximum deflection not to exceed L/200. Uniformly distributed load L = Supporting interval of sub-structure The above conditions are expressed with equations in the following manner: (1) Stress Z > W L 2 / (8 Stress 0.2 ) where, Z: Section modulus of sub-structure (mm 3 ) W: Wind load on sub-structure (N/mm) L: Supporting interval of sub-structure (mm) Stress 0.2 : 0.2% proof stress of sub-structure (N/mm 2 ) (2) Deflection 5 W L 4 / 384 E I < (L/200) where, E: Modulus of elasticity of sub-structure (N/mm 2 ) I: Moment of inertia of sub-structure (mm 4 ) L 2. Calculation example 2-1. Premise (1) Wind load: 1.0kPa (1.0kN/m 2 = 98kg/m 2 ) (2) Panel width: 1200mm (3) Supporting interval: L (mm, to be determined) (4) Sub-structure: L40 40 3.0mm made of steel or aluminum, as shown below: Section Moment of inertia Section modulus 0.2% proof stress Modulus of elasticity 1.0 kpa Sub-structure material Steel Aluminum L40 40 3.0mm I = 3.53 10 4 mm 4 Z = 0.121 10 4 mm 3 Stress 0.2 = 235N/mm 2 Stress 0.2 = 117N/mm 2 E = 210kN/mm 2 E = 70kN/mm 2 1200 2-2. Wind load on sub-structure W = w B = 1000N/m 2 10-6 mm 2 /m 2 1200mm = 1.20N/mm B: Loading width as shown in the diagram below 33
Guidance for Designing Appendix 4 2-3. In case of steel sub-structure [Stress] Z > W L 2 / (8 Stress 0.2 ) 0.121 10 4 > 1.20 L 2 /(8 235) L < 1377 mm B=1200 ALPOLIC panel Sub-structure PW=1200 [Deflection] 5 W L 4 / 384 E I < (L/200) 5 1.20 L 4 / 384 210000 3.53 10 4 < (L/200) L < 1333 mm PW=1200 To meet both stress and deflection conditions, L < 1333 mm. Namely, the supporting interval must be smaller than 1333 mm. 2-4. In case of aluminum sub-structure [Stress] Z > W L 2 / (8 Stress 0.2 ) 0.121 10 4 > 1.20 L 2 /(8 117) L < 971 mm [Deflection] 5 W L 4 / 384 E I < (L/200) 5 1.20 L 4 / 384 70000 3.53 10 4 < (L/200) L < 925 mm To meet both stress and deflection conditions, L < 925 mm. Namely, the supporting interval must be smaller than 925 mm. 2-5. Conclusion The calculated results are summarised as follows: Sub-structure material Supporting interval Steel < 1333 mm Aluminum < 925 mm 3. Support intervals of sub-structure for general purpose The following charts are calculation results for suitable intervals of L-40 40 3mm made of steel or aluminum. This calculation is based on the following premise: Sub-structure material Steel L-40 40 3mm Galvanised or coated with rust-preventive paint AluminumL-40 40 3mm Alloy: 6063 T5 Moment of inertia I = 3.53 10 4 mm 4 I = 3.53 10 4 mm 4 Section modulus Z = 0.121 10 4 mm 3 Z = 0.121 10 4 mm 3 Permissible stress Stress P = 210N/mm 2 Stress P = 118N/mm 2 (including safety factor=1.25) Modulus of elasticity E = 210kN/mm 2 E = 70kN/mm 2 34
Guidance for Designing Appendix 4 Steel L-40 40 3mm Aluminum L-40 40 3mm 4.0 4.0 3.5 3.0 PW=900 3.5 3.0 PW=900 Wind Load ( 2.5 2.0 1.5 PW=1200 PW=1500 Wind Load ( 2.5 2.0 1.5 PW=1200 PW=1500 1.0 1.0 0.5 0.5 0.0 300 600 900 1200 1500 1800 2100 Supporting Interval (mm ) 0.0 600 600 900 1200 1500 1800 2100 Supporting Interval (mm) 35
Guidance for Designing Appendix 5 Strength of junction hole Rivet, bolt/nut and tapping screw are quite often used for junction between ALPOLIC panels and aluminum profiles. When tensile force loads on the junction point, stress will arise in the junction hole of ALPOLIC panel. In order to evaluate the maximum elastic limit of junction hole, test was performed. The results are shown in the table below: Aluminum profile ALPOLIC Test method for junction hole To utilize this table, we convert the stress to tensile force with the following equation: F = Stress t D Where, Stress: Maximum elastic stress (N/mm 2 ) F: Maximum tensile force (N) t: Thickness of ALPOLIC D: Hole diameter Calculation example: Premise: ALPOLIC 305, D = 4 mm, e = 8 mm, Result: F = Stress t D = 48 3 4 = 576 N per junction point Hole diameter D (mm) Hole center to panel edge e (mm) Max. elastic stress (N/mm 2 ) Max. tensile force, F (N) 3mm 4mm 6mm 3mm 4mm 6mm 5 5 21 23 18 320 430 530 10 48 44 38 720 880 1150 15 55 46 40 820 920 1210 10 9 20 21 17 590 820 1000 19 38 33 25 1150 1330 1530 30 39 38 25 1170 1530 1470 It is understood from the above table that, if the hole position is in the proximity of edge, the hole strength lessens to one half of its original strength. In order to ensure a reasonable strength of junction hole, the distance from the center of hole to the edge (e) should be larger than double of hole-diameter (D): namely, e > 2 D. 36
Guidance for Designing Appendix 6 Heat Transmission of External Cladding 1. Mechanism of heat transmission The heat transmits by three mechanisms of radiation, convection and conduction: Radiation: The heat transmission by a thermal energy, evolved from an object, reaching another object, to increase the latter temperature. Convection: The heat transmission by movement of fluid, like air or water. When a part of fluid is warmed, and then, the part of fluid moves upward due to the lightened density. Conduction: The internal heat transmission in solid material. 2. Heat conduction Among these mechanisms, the heat transmission dealt with external claddings is primarily dependent on the heat conduction of the wall materials. When a temperature difference exists between both sides of wall, heat flows from the higher temperature end to the lower temperature end by heat conduction, and the speed of heat flow is defined as the heat conductivity, which is expressed by the following equation: Q = (L/ d) (t 1 -t 2 ) where Q: Total heat flow by heat transmission (kcal/m 2 h) L: Heat conductivity (kcal/mh C) t 1, 2 : Surface temperature of wall ( C) d: Wall thickness (m) Fig. 1, Heat Conduction t 1 Extern al wall d t 2 The heat conductivity of ALPOLIC/fr is given as a combined conductivity of aluminum and core material, and it is a relatively small value, compared with aluminum and steel. The heat conductivity of various wall materials is summarized in Table 1. Materials Table 1, Heat Conductivity of Various Wall Materials Heat Conductivity kcal/mh C Materials Heat Conductivity kcal/mh C Materials ALPOLIC/fr 3mm 0.43 Float Glass 0.86 Gypsum Board 0.11 ALPOLIC/fr 4mm 0.39 Granite 2.50 Rock Wool 0.035 ALPOLIC/fr 6mm 0.35 Concrete 1.40 Glass Wool 0.035 Aluminum Sheet 180.0 Mortar 1.30 Polyurethane Foam 0.035 Steel Sheet 39.0 Brick 0.24 Styrofoam 0.030 3. Heat transmission Apart from the heat conduction through wall materials, there is another heat flow in the interface between the wall and the adjacent air. This heat flow of interface, caused by a concurrent occurrence of heat radiation, convection and conduction, is called the heat transfer. Heat Conductivity kcal/mh C 37
Guidance for Designing Appendix 6 When there is a temperature difference in atmosphere between both sides of wall, the heat flows from the higher temperature to the lower temperature, through the heat transfer (air to wall), heat conduction inside the wall and heat transfer (wall to air). The overall heat flow process is called the heat transmission. This process can be expressed by the following equation: Q = K (t 1 -t 2 ) K = 1 / (1/A o + d/l+ 1/A i ) Where Q: Total heat flow by heat transmission (kcal/m 2 h) K: Heat transmission coefficient (U Value, kcal/m 2 h C) t 1, 2 : Atmospheric temperature around wall ( C) A o, i : Heat transfer coefficients (kcal/m 2 h C) L: Heat conductivity (kcal/mh C) d: Wall thickness (m) Outdoor Fig. 2, Heat Transmission t 1 External wall A o d/l A i Fig. 3, Heat Transmission of Actual Wall t 2 Indoor The above K-value, called the heat transmission coefficient, indicates the easiness of heat flow through the wall. The lower the K-value is, the thermal insulation of the wall system becomes better. This value is also called U-value and expressed in W/(m 2 K) in the SI unit in accordance with ISO. The values can be converted each other by the following equation: W/(m 2 K) 0.86 = kcal/m 2 h C Outdoor 1' 1 2 3 Indoor 4 5 5' 4. Heat transmission of actual wall The heat transmission coefficient of actual wall system, as shown in Fig. 3, can be calculated by summing up each component of heat flow, from the outer surface of ALPOLIC/fr panel to the inner surface of interior material. Refer to Table 2. 1: ALPOLIC/fr 4mm 2: Air space 100mm 3: Brick wall 115mm 4: Air space 50mm 5: Gypsum board 12mm Table 2, Example of Calculation of Heat Transmission Coefficient No. Component of heat flow Equation Value, kcal/m 2 h C 1' Heat transfer from outer air to ALPOLIC/fr 1/A o 0.05 1 Internal heat conduction in ALPOLIC/fr d 1 /L 1 0.004/0.39=0.01 2 Internal heat transfer in air space d 2 /L 2 0.10 3 Internal heat conduction in brick wall d 3 /L 3 0.115/0.24=0.48 4 Internal heat transfer in air space d 4 /L 4 0.10 5 Internal heat conduction in gypsum board d 5 /L 5 0.012/0.11=0.11 5' Heat transfer from gypsum board to inner air 1/A I 0.13 Total 1/K=1/A o +Σd i /L i +1/A i 1/K=0.98 K=1.02 kcal/m 2 h C 38
Guidance for Designing Appendix 6 Generally, the heat transmission coefficient of actual wall system can be expressed with the following equation: 1/K = 1/A o +Σd i /L i +1/A I Where, d i /L i : Heat conduction of each wall materials or heat transfer of air space 3. Heat transmission coefficient of various wall system By means of the above equation, the heat transmission coefficient can be calculated for various types of wall systems. In order to clarify the insulation effect of ALPOLIC/fr, the heat transmission coefficient, K-value or U- value, was calculated for some typical wall systems, in which the components constituting the wall system were selected among the following alternatives: Wall component 1. External cladding (1) ALPOLIC/fr (2) Solid aluminum panel (3) Float glass 2. Thermal insulation (1) None (2) Glass wool 25mm (3) Glass wool 50mm 3. Structural wall or fireproof (1) RC wall material (2) Brick wall (3) Gypsum board 16+16mm 4. Interior material (1) None (2) Gypsum board 12mm Outdoor Indoor 1 3 2 4 39
Guidance for Designing Appendix 6 Table 3, Heat transmission coefficient of external wall (1) ALPOLIC/fr 3mm only Wall System (Thickness, mm) Heat Transmission Coefficient (U Value) kcal/m 2 h C (W/m 2 K) 5.4 (6.2) Heat Absorbing Float Glass Bronze 6mm Wall System (Thickness, mm) Heat Transmission Coefficient (U Value) kcal/m 2 h C (W/m 2 K) 5.0 (5.8) ALPOLIC/fr 4mm only 5.3 (6.1) High Performance Reflective Glass 6mm 3.9-4.6 (4.6-5.4) ALPOLIC/fr 6mm only Aluminum Sheet 3mm 5.1 (5.9) Double Glazing Glass, Reflective Glass 6mm + Airspace 12mm +FL6 5.6 (6.5) Polycarbonate Sheet, Clear 3mm 1.5-2.3 (1.9-2.6) 5.2 (6.0) Aluminum Sheet 4mm 5.6 (6.5) ALPOLIC/fr 4 Air Space 50 Gypsum Board 12 2.5 (2.9) Float Glass Clear 3mm 5.1 (6.0) Reinforced Concrete 100mm 4.0 (4.6) Float Glass Clear 6mm 5.0 (5.8) Reinforced Concrete 150mm 3.5 (4.1) ALPOLIC/fr 4 Air Space 100 RC Wall 100 2.8 (3.2) Brick Wall 115 Air Space 50 Gypsum Board 12 1.2 (1.3) 40
Guidance for Designing Appendix 6 Table 3, Heat transmission coefficient of external wall (1) Wall System (Thickness, mm) RC Wall 100 Air Space 50 Gypsum Board 12 ALPOLIC/fr 4 Air Space 100 RC Wall 100 Air Space 50 Gypsum Board 12 ALPOLIC/fr 4 Air Space 75 Glass Wool 25 RC Wall 100 Gypsum Board 12 ALPOLIC/fr 4 Air Space 50 Glass Wool 50 RC Wall 100 Air Space 50 G. Board 12 Brick Wall 115mm ALPOLIC/fr 4 Air Space 100 Brick Wall 115 ALPOLIC/fr 3mm Air Space 100 G. Board 16, Air Space 50, G. Board 16 ALPOLIC/fr 6mm Air Space 100 G. Board 16, Air Space 50, G. Board 16 Heat Transmission Coefficient (U Value) Wall System (Thickness, mm) kcal/m 2 h C (W/m 2 K) 2.2 (2.5) ALPOLIC/fr 4 Air Space 100 Brick Wall 115 Air space 50 Gypsum Board 12 1.8 (2.1) ALPOLIC/fr 4 Air Space 75 Glass Wool 25 Brick Wall 115 Air space 50 G. Board 12 0.79 (0.92) ALPOLIC/fr 4 Air Space 50 Glass Wool 50 Brick Wall 115 Air space 50 G. Board 12 0.50 (0.58) ALPOLIC/fr 4 Air Space 100 Gypsum Board 16, Air Space 50, Gypsum Board 16 1.5 (1.8) ALPOLIC/fr 4 Air Space 75 Glass Wool 25, G. Board 16, Air Space 50, G. Board 16 1.3 (1.5) ALPOLIC/fr 4 Air Space 50 Glass Wool 50, G. Board 16, Air Space 50, G. Board 16 1.48 (1.72) Aluminum Panel 3mm Air Space 100 G. Board 16, Air Space 50, G. Board 16 1.46 (1.69) Aluminum Panel 4mm Air Space 100 G. Board 16, Air Space 50, G. Board 16 Heat Transmission Coefficient (U Value) kcal/m 2 h C (W/m 2 K) 1.0 (1.2) 0.59 (0.69) 0.42 (0.48) 1.5 (1.7) 0.72 (0.83) 0.47 (0.55) 1.49 (1.74) 1.49 (1.74) 41
Guidance for Designing Appendix 7 General performance of sealant Silicone sealant is widely known for its excellent long-term performance such as durability, thermal resistance and adhesion reliability. The following table shows general comparison among sealing materials for exterior. General performance Sealing Materials Silicone Modified silicone Polysulfide Polyuretha ne Restoring ability A A-B B B Degradation Due to aging VS S-M M M Due to temperature VS S-M M-L M Shrinkage after filling S S S S Serviceable temperature (long-term) -40/120 C -30/90 C -20/80 C -20/70 C Weatherability A A-B A-B B Fatigue resistance A A-B B A-B Note 1: A: Excellent B: Good C: Normal VS: Very small S: Small M: Medium L: Large Note 2: The above is excerpt from Sealing Material Handbook, Japan Sealant Manufacturers Association. But silicone sealant is also known for its staining problem. Especially, if silicone sealant is applied for natural stone wall, in which many small cavities exist on the surface, the staining problem becomes serious. The following table is excerpt from Architectural Technology No.4, P.90-93, 1993, architectural magazine published in Japan, focusing on the staining tendency of each sealing material. Recently, silicone sealant manufacturers have developed the less staining silicone sealant. The following table was prepared before this new type silicone emerged. Stain Sealing Materials Silicone Modified silicone Polysulfide Polyuretha ne Surrounding area Due to dispersed component C A A A Sealing joint surface Due to dust adhesion C B A C Due to mold grow B B B B Color fading Due to UV & sulfur A A B C (Note) A: No affect, B: Small affect, C: Affect 42
Guidance for Designing Appendix 8 Protection of ALPOLIC/fr Panels against Lightning 1. General understanding In the event that lightning should strike the ALPOLIC/fr panel of external cladding, what will happen on the panel and the building? Generally speaking, external cladding panels constitute an electric circuit together with the sub-structure, which is finally connected to the ground earth. Therefore, it is a general understanding that the lightning electricity will flow toward the ground through the electric circuit, and nothing will happen on the panel and the building. Ground earth Lightning rod External cladding But, to be safe, we are going to verify the electric behavior of ALPOLIC/fr panel of external cladding more in detail, particularly when lightning strikes ALPOLIC/fr panel. Fig. 1, Lightning on ALPOLIC/fr panel 2. Requirements for electric-conducting wire to release lightning electricity When lightning strikes ALPOLIC panel of external cladding and the electricity flows through the electric circuit consisting of ALPOLIC panels and their sub-structure, if the electric resistance of the circuit is low enough, the electricity will pass through the circuit, like a electric-conducting wire, toward the ground. Thus, in order to act as a suitable electric-conducting wire to release the lightning electricity, the electric resistance of external cladding and sub-structure must be low enough. In accordance with JIS A 4201 "The protection of structures against lightning," the requirements for electric-conducting wire of lightning rod is standardized as follows: (1) To provide every wire within 50m interval of perimeter of the building. (2) The electric resistance of each wire shall be lower than 50 ohm and the overall resistance shall be lower than 10 ohm. 3. Electric resistance of ALPOLIC panels and sub-structure According to the above standard, we would like to evaluate whether the electric resistance is low enough in ALPOLIC panels and sub-structure system. In order to evaluate the electric resistance, one model of external cladding was used: a rectangular solid building of 25m by 25m by 100m high, as shown in Fig.2. ALPOLIC cladding and sub-structure are assumed to be surrounding the whole building. The installation method is assumed as Fig. 3. Sub-structure, coated steel, is fixed to the concrete slab with bracket and anchor. ALPOLIC panels are fixed onto the sub-structure with screw of stainless steel. 25m ALPOLIC & sub-structu 25m 100m Fig. 2, Model for calculation 43
Guidance for Designing Appendix 8 As the surfaces of ALPOLIC and sub-structure are coated with paint, both surfaces are electrically insulated. Junction by screw @=1.5m Bracket & anchor Junction by rivet ALPOLIC panel Vertical sub-structure Horizontal sub-structure Fig. 3, Installation details Therefore, the electrical connection between ALPOLIC panel and sub-structure will be ensured by means of junction points by rivets (aluminum) and screws (stainless steel) in this model. Based on the above assumption, when the contact resistance of these junction points is disregarded, the electric resistance of ALPOLIC panel and sub-structure from the building top and to the ground can be calculated as follows: Table 1. Calculated electric resistance of external cladding ALPOLIC (aluminum skin of Sub-structure (steel, 100 50 2mmt) surface side, 0.5mmt) Specific resistance of aluminum and steel Sectional area of metals 0.05m 2 0.027m 2 in the model Electric resistance from top to bottom Combined resistance of aluminum and steel 4 10-8 ohm m 10 10-8 ohm m - - (0.5 10-3 25m 4) (0.2 2 10-3 66pcs.) 0.8 10-4 ohm 3.7 10-4 ohm 0.66 10-4 ohm As shown in the above table, it is confirmed that the calculated resistance of external cladding is very low, compared with the standard value of 10ohm. 4. Survey at ALPOLIC project To confirm the above calculation, we held a survey at actual ALPOLIC project (total ALPOLIC area is 300m 2, as shown in Fig.4), to measure the actual electric resistance between two ALPOLIC panels of different distance. We also measure the resistance between ALPOLIC panel and the principal earth of the building. The result is shown in Table 2. 44
Guidance for Designing Appendix 8 Table 2. Result of survey at actual ALPOLIC project Measured points Distance between two points points Resistance between two One ALPOLIC panel to 10m 0.2 ohm another ALPOLIC panel 20m 0.3 ohm 30m 0.2 ohm One ALPOLIC panel to the 10m 0.0 ohm principal earth of the building 20m 0.2 ohm Fig. 4, ALPOLIC project where the survey was held 5. Difference between ALPOLIC panel and solid aluminum panel Based on the same model mentioned above, the resistance of solid aluminum panel can be calculated as follows: Table 3. Calculated electric resistance of solid aluminum panel Solid aluminum panel Sub-structure (aluminum 3.0mmt) (steel, 100 50 2mmt) Specific resistance of aluminum and steel Sectional area of metals in the model Electric resistance from top to bottom Combined resistance of aluminum and steel 4 10-8 ohm m 10 10-8 ohm m - 0.3m 2 0.027m 2 - (3.0 10-3 25m 4) (0.2 2 10-3 66pcs.) 0.13 10-4 ohm 3.7 10-4 ohm 0.13 10-4 ohm From Table 1 and 3, the resistance of ALPOLIC external cladding can be compared with that of solid aluminum panel as follows: ALPOLIC Solid aluminum panel 3.0mm Combined resistance of aluminum and steel 0.66 10-4 ohm 0.13 10-4 ohm Compared with the standard of 10ohm and the contact resistance of the junction points, both resistances are very small and the difference between two seems to be in a negligible range. 45